Offline 600W Battery Charger:
PFC + LLC with HR1211
REFERENCE DESIGN
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The EVHR1211-Y-00B is an evaluation board for lithium-ion batteries, which are typically used in e-mobility and uninterruptible power supply (UPS) applications. The EVB can also be used as a general power supply unit. The device regulates the output voltage to 58.8V if there is not a battery present. This solution is based on a PFC + LLC combo controller from a single integrated circuit (the HR1211).
Instead of using costly, low-frequency filters, the EVHR1211-Y-00B offers excellent power factor levels with active power factor correction (PFC). The design shows high power density with low overall cost. In the place of diodes, synchronous rectification (SR) reduces the voltage drop, and constant current (CC) and constant voltage (CV) control ensures the battery is charged properly.
Lithium-ion batteries generally require a battery management system (BMS) to ensure that the battery operates within safe parameters. This charger can interact with a BMS through a relay signal. This helps prevent high-current spikes in the output connection, which can trigger BMS protections.
Electromagnetic compatibility (EMC) tests, harmonic emission tests, and no-load consumption tests were utilized to ensure that this solution meets industry standards.
Features
- Wide 85V to 265V Operating Input Range
- 14S battery configuration (3.6V)
- High Efficiency, Up to 92%
- Meets EuP Lot 6 and COC Version 5 Tier 2 Specifications
- Meets Class A IEC61000-3-2 Standards
- Meets EN55032 Class B Standards
- High Power Factor (PF)
- Overload Protection (Auto-Restart Mode)
- Short-Circuit Protection (SCP) (Auto-Restart Mode)
- Over-Voltage Protection (OVP)
- Anti-Capacitive Mode Protection
- Form Factor: 190 mm x 100 mm x 50 mm (3U rack STD)
Applications
- e-Bike Battery Chargers
- Rack UPS
Block Diagram
Related Solutions
| MPS Integrated Circuit | Description |
| HR1211 | High-performance digital PFC + LLC combo controller |
| HF500-15 | Fixed-frequency flyback regulator |
| MP6925A | Synchronous Rectifier (SR) controller |
| MP2009 | Low Drop Out (LDO) voltage regulator |
System Specifications
| Parameter | Specification |
| Input voltage range | 85VAC to 265VAC |
| Output voltage range | 35VDC to 58.8VDC (±1.5%) |
| Output current | 10A (±1.5%) |
| Normal conditions | Input: 230VAC, output: 50.4VDC/10A (14S Li-ion STD) |
| Board form factor | 220mm x 100mm x 50mm |
| Efficiency | >92% |
| Standby power consumption | Meets EuP Lot 4 and COC Version 5 Tier 2 (<500mW at 265V) standards |
| Conducted emissions | Meets Class B EN55032 standards |
| Output voltage ripple | ±100mV at full load |
| Output current ripple | ±485mA at full load |
Test Overview
Efficiency Vs. Load
Output Current vs. Output Voltage
Current Harmonic Distribution
Efficiency Vs. Input Voltage
Power Factor
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